KYMCO People S 250 User manual

KYMCO
Brand
KYMCO
Model
People S 250
Category
Motorcycles
Type
User manual

This manual is also suitable for

KYMCO People S 250 is a high-performance motorcycle with a variety of features that make it an excellent choice for commuting, touring, and everyday riding. Some of its capabilities include:

  • KYMCO People S 250 is powered by a water-cooled 4-stroke, OHC engine that produces 20.1 ps at 7500 rpm and 2.1 kg-m of torque at 6500 rpm, giving it plenty of power for highway riding and overtaking.
  • It has a fuel capacity of 10 liters, which gives it a range of over 250 kilometers on a single tank of gas.
  • KYMCO People S 250 is equipped with a dry multi-disc clutch and a non-stage transmission with automatic centrifugal operation, making it easy to ride, even for beginners.

KYMCO People S 250 is a high-performance motorcycle with a variety of features that make it an excellent choice for commuting, touring, and everyday riding. Some of its capabilities include:

  • KYMCO People S 250 is powered by a water-cooled 4-stroke, OHC engine that produces 20.1 ps at 7500 rpm and 2.1 kg-m of torque at 6500 rpm, giving it plenty of power for highway riding and overtaking.
  • It has a fuel capacity of 10 liters, which gives it a range of over 250 kilometers on a single tank of gas.
  • KYMCO People S 250 is equipped with a dry multi-disc clutch and a non-stage transmission with automatic centrifugal operation, making it easy to ride, even for beginners.
PEOPLE/PEOPLE S 250
By KWANG YANG Motor Co., Ltd.
First Edition, Jan 2006
All rights reserved. Any reproduction or
unauthorized use without the written
permission of KWANG YANG Motor Co., Ltd.
is expressly prohibited.
4122-LLJ3/LDH1-S00
PEOPLE/PEOPLE S 250
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO
People/People s 250.
Section 1 contains the precautions
for all operations stated in this
manual. Read them carefully before
any operation is started.
Section 2 is the removal/installation
procedures for the frame covers which
are subject to higher
removal/installation frequency during
maintenance and servicing
operations.
Section 3 describes the inspection/
adjustment procedures, safety rules
and service information for each part,
starting from periodic maintenance.
Sections 5 through 13 give
instructions for disassembly, assembly
and adjustment of engine parts.
Section 14 is the removal/ installation
of chassis. Section 16 states the
testing and measuring methods of
electrical equipment.
Most sections start with an assembly
or system illustration and
troubleshooting for the section. The
subsequent pages give detailed
procedures for the section.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
TABLE OF CONTENTS
GENERAL INFORMATION
1
EXHAUST MUFFLER/FRAME COVERS
2
INSPECTION/ADJUSTMENT
3
LUBRICATION SYSTEM
4
ENGINE REMOVAL/INSTALLATION
5
CYLINDER HEAD/VALVES
6
CYLINDER/PISTON
7
DRIVE AND DRIVEN PULLEYS/V-
BELT
8
FINAL REDUCTION
9
A.C. GENERATOR/STARTER
CLUTCH
10
CRANKCASE/CRANKSHAFT
11
COOLING SYSTEM
12
FUEL SYSTEM/CARBURETOR/FUEL
PUMP FUEL TANK
13
STEERING HANDLEBAR/FRONT
WHEEL/FRONT BRAKE/FRONT
SHOCK ABSORBER/FRONT FORK
14
REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER`
15
BATTERY/CHARGING SYSTEM
16
IGNITION SYSTEM
17
STARTING SYSTEM
18
SWITCHES/HORN/FUEL UNIT/
THERMO-STATIC
SWITCH/TEMPERATURE
GAUGE/INSTRUMENTS/ LIGHTS
19
The information and contents included
in this manual may be different from the
motorcycle in case specifications are
changed.
CHASSIS
ELECTRICAL
EQUIPMENT
ENGINE
1. GENERAL INFORMATION
1-0
PEOPLE/PEOPLE S 250
1
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
GENERAL INFORMATION
________________________________________________________________________________
SERIAL NUMBER------------------------------------------------------------------------------------1-1
SPECIFICATION -------------------------------------------------------------------------------------1-2
SERVICE PRECAUTIONS-------------------------------------------------------------------------1-4
TORQUE VALUES-----------------------------------------------------------------------------------1-8
SPECIAL TOOLS-------------------------------------------------------------------------------------1-9
LUBRICATION POINTS -------------------------------------------------------------------------- 1-10
CABLE & HARNESS ROUTING------------------------------------------------------------------- 1-12
WIRING DIAGRAM--------------------------------------------------------------------------------------------- 1-20
TROUBLESHOOTING ---------------------------------------------------------------------------- 1-22
1
1. GENERAL INFORMATION
1-1
PEOPLE/PEOPLE S 250
SERIAL NUMBER
Location of Engine Serial Numbe
r
Location of Frame Serial Numbe
r
1. GENERAL INFORMATION
1-2
PEOPLE/PEOPLE S 250
SPECIFICATIONS
Name & Model No. BC50AA
Motorcycle Name & Type PEOPLE 250
Overall length 2130mm
Overall width 750mm
Overall height 1170mm
Wheel base 1430mm
Engine type Water cooled 4-stroke,
OHC engine
Displacement 251/249.1cc
Fuel Used 92# nonleaded
gasoline
1 person (55kg) Front wheel 86
weight (kg) Rear wheel 127
Total 213
2 person (110kg) Front wheel 93
weight(kg) Rear wheel 175
Total 268
Front wheel 110/70-16 52P
Rear wheel 140/70-16 65P
Ground clearance 140mm
Perform- Braking distance (m) 4.0m/30km/hr
ance Min. turning radius 2350mm
Starting system Starting motor
Type Gasoline, 4-stroke
Cylinder arrangement Single cylinder
Combustion chamber type Semi-sphere
Valve arrangement O.H.C.
Bore x stroke (mm) 72.7 x 60
Compression ratio 10.3:1
Compression pressure
(kg/cm²)15±2
Max. output (ps/rpm) 18.3/7000
Max. torque (kg.m/rpm) 2.0/5500
BTDC -8°
Port Intake ABDC 42°
timing BBDC 33°
Exhaust ATDC 1°
Valve Intake 0.1
clearance (cold) Exhaust 0.1
Idle speed (rpm) 1700±100rpm
Lubrication type Forced pressure &
Wet sump
Oil pump type Inner/outer rotor type
Oil filter type Full-flow filtration
Oil capacity 1.1 liters
Cooling Type Water cooling
Air cleaner type & No Paper element, wet
Fuel capacity 8.5 liters
Type CVK
Piston dia. 30
Venturi dia. 30 equivalent
Throttle type Butterfly type
Type Full transistor igniter
Ignition timing Repeatedly
Contact breaker Non-contact point type
Spark plug NGK
DPR7EA-9
Spark plug gap 0.7mm
Battery Capacity 12V10AH
Clutch Type Dry multi-disc clutch
Type Non-stage
transmission
Operation Automatic centrifugal
Type
Type Two-stage reduction
Reduction 1st 0.83~2.2
ratio Fina
l8.72
Front 1.75
Tire pressure
(kgf/cm²)Rear 2.0
Turning Left 45°
angle Right 45°
Front Disk brake
Brake system
type Rear Disk brake
Sus
p
ension Front Telescope
type Rear Double swing
Shock absorber Front Telescope
type Rear Double swing
Frame type Under bone
Tires
En
g
ine
Lubrication
S
y
stem
Fuel S
y
stem
Carburetor
Electrical Equipment
I
g
nition S
y
stem
Power Drive System
Transmis-
sion Gear Reduction
Gear
Moving
Device Damping
Device
1. GENERAL INFORMATION
1-3
PEOPLE/PEOPLE S 250
SPECIFICATIONS
Name & Model No. BA50AA
Motorcycle Name & Type PEOPLE S 250
Overall length 2140mm
Overall width 750mm
Overall height 1370mm
Wheel base 1480mm
Engine type Water cooled 4-stroke,
OHC engine
Displacement 251/249.1cc
Fuel Used 92# nonleaded
gasoline
1 person (55kg) Front wheel 86
weight (kg) Rear wheel 127
Total 213
2 person (110kg) Front wheel 93
weight(kg) Rear wheel 175
Total 268
Front wheel 110/70-16 52P
Rear wheel 140/70-16 65P
Ground clearance 145mm
Perform- Braking distance (m) 4.0m/30km/hr
ance Min. turning radius 2350mm
Starting system Starting motor
Type Gasoline, 4-stroke
Cylinder arrangement Single cylinder
Combustion chamber type Semi-sphere
Valve arrangement O.H.C.
Bore x stroke (mm) 72.9 x 60/72.7 x 60
Compression ratio 10.3:1
Compression pressure
(kg/cm²)15±2
Max. output (ps/rpm) 20.1/7500
Max. torque (kg.m/rpm) 2.1/6500
BTDC 9°
Port Intake ABDC 40°
timing BBDC 42°
Exhaust ATDC 7°
Valve Intake 0.1
clearance (cold) Exhaust 0.1
Idle speed (rpm) 1600±100rpm
Lubrication type Forced pressure &
Wet sump
Oil pump type Inner/outer rotor type
Oil filter type Full-flow filtration
Oil capacity 1.1 liters
Cooling Type Water cooling
Air cleaner type & No Paper element, wet
Fuel capacity 10.0 liters
Type CVK
Piston dia. 30
Venturi dia. 30 equivalent
Throttle type Butterfly type
Type Full transistor igniter
Ignition timing Repeatedly
Contact breaker Non-contact point type
Spark plug NGK
DPR7EA-9
Spark plug gap 0.7mm
Battery Capacity 12V10AH
Clutch Type Dry multi-disc clutch
Type Non-stage
transmission
Operation Automatic centrifugal
Type
Type Two-stage reduction
Reduction 1st 0.83~2.2
ratio Fina
l8.72
Front 1.75
Tire pressure
(kgf/cm²)Rear 2.0
Turning Left 45°
angle Right 45°
Front Disk brake
Brake system
type Rear Disk brake
Sus
p
ension Front Telescope
type Rear Double swing
Shock absorber Front Telescope
type Rear Double swing
Frame type Under bone
Tires
En
g
ine
Lubrication
S
y
stem
Fuel S
y
stem
Carburetor
Electrical Equipment
I
g
nition S
y
stem
Power Drive System
Transmis-
sion Gear Reduction
Gear
Moving
Device Damping
Device
1. GENERAL INFORMATION
1-4
PEOPLE/PEOPLE S 250
SERVICE PRECAUTIONS
Make sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when
reassembling.
When tightening bolts or nuts, begin with
larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.
Use genuine parts and lubricants.
When servicing the motorcycle, be sure to
use special tools for removal and
installation.
After disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil
before reassembly.
Apply or add designated greases and
lubricants to the specified lubrication
points.
After reassembly, check all parts for proper
tightening and operation.
When two persons work together, pay
attention to the mutual working safety.
Disconnect the battery negative (-) terminal
before operation.
When using a spanner or other tools, make
sure not to damage the motorcycle surface.
After operation, check all connecting points,
fasteners, and lines for proper connection
and installation.
When connecting the battery, the positive
(+) terminal must be connected first.
After connection, apply grease to the
battery terminals.
Terminal caps shall be installed securely.
1. GENERAL INFORMATION
1-5
PEOPLE/PEOPLE S 250
If the fuse is burned out, find the cause and
repair it. Replace it with a new one
according to the specified capacity.
After operation, terminal caps shall be
installed securely.
When taking out the connector, the lock on
the connector shall be released before
operation.
Hold the connector body when connecting
or disconnecting it.
Do not pull the connector wire.
Check if any connector terminal is bending,
protruding or loose.
The connector shall be inserted
completely.
If the double connector has a lock, lock
it at the correct position.
Check if there is any loose wire.
Before connecting a terminal, check for
damaged terminal cover or loose negative
terminal.
Check the double connector cover for
proper coverage and installation.
Insert the terminal completely.
Check the terminal cover for proper
coverage.
Do not make the terminal cover opening
face up.
Secure wire harnesses to the frame with
their respective wire bands at the
designated locations.
Tighten the bands so that only the
insulated surfaces contact the wire
harnesses.
Confirm
Capacity
1. GENERAL INFORMATION
1-6
PEOPLE/PEOPLE S 250
After clamping, check each wire to make
sure it is secure.
Do not squeeze wires against the weld or
its clamp.
After clamping, check each harness to
make sure that it is not interfering with any
moving or sliding parts.
When fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.
Route wire harnesses to avoid sharp edges
or corners. Avoid the projected ends of
bolts and screws.
Route wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.
Route harnesses so they are neither
pulled tight nor have excessive slack.
Protect wires and harnesses with electrical
tape or tube if they contact a sharp edge or
corner.
When rubber protecting cover is used to
protect the wire harnesses, it shall be
installed securely.
Do not break the sheath of wire.
If a wire or harness is with a broken sheath,
repair by wrapping it with protective tape or
replace it.
When installing other parts, do not press or
squeeze the wires.
Do not pull
too tight
No Contact
Do not press or
squeeze the wire
1. GENERAL INFORMATION
1-7
PEOPLE/PEOPLE S 250
After routing, check that the wire harnesses
are not twisted or kinked.
Wire harnesses routed along with
handlebar should not be pulled tight, have
excessive slack or interfere with adjacent
or surrounding parts in all steering
positions.
When a testing device is used, make sure
to understand the operating methods
thoroughly and operate according to the
operating instructions.
Be careful not to drop any parts.
When rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.
Symbols:
The following symbols represent the
servicing methods and cautions included in
this service manual.
: Apply engine oil to the
specified points. (Use
designated engine oil for
lubrication.)
: Apply grease for lubrication.
: Transmission Gear Oil (90#)
: Use special tool.
: Caution
: Warning
Special
Engine Oil
Grease
Gear Oil
Do you understand
the instrument
Remove Rust
1. GENERAL INFORMATION
1-8
PEOPLE/PEOPLE S 250
TORQUE VALUES
STANDARD TORQUE VALUES
Item Torque (N-m) Item Torque (N-m)
5mm bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut
4.5～6
8～12
18～25
30～40
50～60
5mm screw
6mm screw, SH bolt
6mm flange bolt, nut
8mm flange bolt, nut
10mm flange bolt, nut
3.5～5
7～11
10～14
24～30
35～45
Torque specifications listed below are for important fasteners.
ENGINE
Item Q‘ty Thread dia.(mm) Torque (N-m) Remarks
Cylinder head bolt A
Cylinder head bolt B
Oil filter screen cap
Cylinder head cap nut
Valve adjusting lock nut
Cam chain tensioner slipper
bolt
Oil bolt
Clutch outer nut
Clutch drive plate nut
Flywheel nut
Oil pump bolt
Cylinder head cover bolt
Spark plug
Cam chain tensioner bolt
Water pump impeller
Drive face nut
Transmission case cover bolt
Gear oil check bolt
2
2
1
4
2
1
1
1
1
1
2
4
1
1
1
1
9
1
8
8
30
8
5
6
12
12
12
14
5
6
10
6
8
12
8
8
8.9
8.9
12.7
24.5
8.8
8.8
14.7
53.9
53.9
58.8
3.9
11.8
17.2
11.8
11.8
93
20
10
Double end bolt
Double end bolt
Apply oil to
threads
1. GENERAL INFORMATION
1-9
PEOPLE/PEOPLE S 250
FRAME
Item Q‘ty Thread dia.(mm) Torque (N-m) Remarks
Steering stem lock nut
Front axle nut
Rear axle nut
Rear shock absorber upper bolt
Rear shock absorber lower bolt
Front shock absorber lock bolt
Engine hanger bolt (frame side)
Engine hanger bolt (ENG. side)
Front caliper holder bolt
Rear caliper holder bolt
Master cylinder holder bolt
Exhaust muffler pipe nut
Exhaust muffler bolt
Rear fork bolt
1
1
1
2
2
4
2
1
2
2
4
2
3
2
10
14
16
10
10
8
12
10
8
8
6
8
8
8
40～50
60～70
110～130
35～45
35～45
29～35
45～55
45～55
24～30
29～35
10～14
18～22
32～38
29～35
SPECIAL TOOLS
Tool Name Tool No. Remarks Ref. Page
Clutch spring compressor E034 Clutch disassembly
Bearing puller 10,12,15,18mm E037 Bearing removal
Valve spring compressor E040 Valve removal
Oil seal & bearing installer E014 Oil seal & bearing install
Tappet adjuster E036 Tappet adjustment
Flywheel puller E003 A.C. generator flywheel removal
Universal holder E017 Holding clutch for removal
Flywheel holder E021 A.C. generator flywheel holding
Lock nut socket wrench F002 Steering stem removal or install
Float level gauge Carburetor fuel level check
1. GENERAL INFORMATION
1-10
PEOPLE/PEOPLE S 250
LUBRICATION POINTS
ENGINE
Lubrication Points Lubricant
Valve guide/valve stem movable part
Camshaft protruding surface
Valve rocker arm friction surface
Camshaft drive chain
Cylinder lock bolt and nut
Piston surroundings and piston ring grooves
Piston pin surroundings
Cylinder inside wall
Connecting rod/piston pin hole
Connecting rod big end
Crankshaft
Cranksahft one-way clutch movable part
Oil pump drive chain
Starter reduction gear engaging part
Countershaft gear engaging part
Final gear engaging part
Bearing movable part
O-ring face
Oil seal lip
•Genuine KYMCO Engine Oil (SAE15W-40)
•API SE, SF or SG Egnine Oil
Starter idle gear
Friction spring movable part/shaft movable part
Shaft movable grooved part
Starter spindle movable part
High-temperature resistant grease
Starter one-way clutch threads Thread locking agent
A.C. generator connector
Transmission case breather tubee Adhesive
1. GENERAL INFORMATION
1-11
PEOPLE/PEOPLE S 250
FRAME
The following is the lubrication points for the frame.
Use general purpose grease for parts not listed.
Apply clean engine oil or grease to cables and movable parts not specified. This will avoid
abnormal noise and rise the durability of the motorcycle.
Seat Lock
Grease
Engine Oil
Grease
Front Brake Lever Pivot
Speedometer Gear/
Front Wheel Bearing
Grease
Rear Fork Bearing
Grease
Speedometer Cable
Throttle Cable
1. GENERAL INFORMATION
1-12
PEOPLE/PEOPLE S 250
CABLE & HARNESS ROUTING
Throttle Cable
Front Brake Fluid Tube
Speedometer Cable
Radiator Ai
Ventilated Tube
(to Radiator)
Rea
r
Brake Fluid Tube
Winker/Horn/DIM Wire
Fuel Tank Cap
Open Cable
Rear Brake Master Cylinde
r
Front Brake Master Cylinde
r
Horn
Radiato
r
1. GENERAL INFORMATION
1-13
PEOPLE/PEOPLE S 250
Front Brake Fluid Tube
Fuel Tank
Inlet Hose
Water Inlet Hose
Fuel Tank
Breather Tube
Radiator Cap
Winker/Horn/DIM Wire
Start/Light/ENG Stop/Passing Wire
Water Outlet Hose
Rea
r
Brake Fluid Tube
Radiator Ai
Ventilated Tube
Fuel Pump
Vacuum Tube
Fuel Hose (between the Fuel Tank and Fuel Filler)
Radiator Air Ventilated
Tube (to Radiator
Water Duct) Radiato
r
Front Brake Calipe
r
Thermostatic Switch
Water Duct Hose
Fuel Pump
Fuel Pump
Outlet Tube
Fuel Tank Cap
1. GENERAL INFORMATION
1-14
PEOPLE/PEOPLE S 250
Throttle Cable
Speedometer Cable
Radiator Air Ventilated
Tube (to Raciator)
Rear Brake Fluid
Tube
Fuel Tank Inlet
Tube
Water Inlet Hose
Fuel Tank
Breather Tube
Wire Harness
Winker/Horn/DIM Wire Start/Light/ENG Stop/Passing Wire
Front Brake Fluid Tube
Fuel Tank
Cap Open
Cable
Radiator Ai
Ventilated Tube
Fan Motor Wire
Ignition Switch
Fuel Tank Cap
1. GENERAL INFORMATION
1-15
PEOPLE/PEOPLE S 250
Starter Relay
Battery (+) Cable
Ignition Coil
Thermosensor Wire
Thermostat
A
ir Inlet Hose (V-belt
Chamber)
A
.C.G/Starte
r
Relay Wire
Ignition Unit
Fuse Box
Fuel Tank Inlet
Tube
Secondary Air Vacuum Tube
Starter Motor wire
Wire Harness
Seat Open
Cable
Battery (-) Cable
Heater Wire
Wire Harness
Fuel Pump
Vacuum Tube
Battery
1. GENERAL INFORMATION
1-16
PEOPLE/PEOPLE S 250
Ignition Coil
Carbureto
r
Secondary Ai
r
Inlet Tube
Fuel Pump
Wire Harness
Fuel Unit
Starter Relay
Oil Vapo
r
Recover
y
Tube
Heater Control Unit
Side Stand Switch
Spark Cap
1. GENERAL INFORMATION
1-17
PEOPLE/PEOPLE S 250
Secondary Air Cleaner Fresh Air Outlet Hose
Ignition Coil
Regulator/
Rectifier
Fuse Box
Fuel Pump
Fuel Unit
Carbureto
r
Battery
Secondary Air Cleane
r
Secondary Ai
r
Cleaner Fresh
Air Inlet Hose
Starter Moto
r
Wire
Fuel Tube (Between Fuel Pump and Fuel Filler)
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KYMCO People S 250 User manual

KYMCO
Brand
KYMCO
Model
People S 250
Category
Motorcycles
Type
User manual
This manual is also suitable for

KYMCO People S 250 is a high-performance motorcycle with a variety of features that make it an excellent choice for commuting, touring, and everyday riding. Some of its capabilities include:

  • KYMCO People S 250 is powered by a water-cooled 4-stroke, OHC engine that produces 20.1 ps at 7500 rpm and 2.1 kg-m of torque at 6500 rpm, giving it plenty of power for highway riding and overtaking.
  • It has a fuel capacity of 10 liters, which gives it a range of over 250 kilometers on a single tank of gas.
  • KYMCO People S 250 is equipped with a dry multi-disc clutch and a non-stage transmission with automatic centrifugal operation, making it easy to ride, even for beginners.
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